Finite element modelling of rubber cutting

An explicit plane strain finite element (FE) model using ABAQUS/Explicit was developed to analyze rubber cutting using high-speed steel (HSS) tools. This chapter describes the finite element analysis procedure of orthogonal rubber cutting, including the design of finite element meshes, and determination of hyperelastic material model coefficient. It presents detailed finite element analysis results, such as cutting forces, chip shape, and stress, strain and strain energy density fields, to gain better understanding of orthogonal rubber cutting process. Cutting forces measured from orthogonal cutting experiments were used to validate the FE model. The FE simulation demonstrates the ability of the model to predict characteristics of rubber cutting process. The model provides new insight into the chip formation process of rubber using the strain energy explanations. With this understanding, guidelines can be developed for operating conditions that result in a smooth machined surface finish for rubber machining.